Mixing valve

ABSTRACT

The present invention relates generally to fluid control valves and, more particularly, to a mixing valve for use within a faucet.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/818,778, filed Jun. 18, 2010, now U.S. Pat. No. 7,980,268,which is a continuation of U.S. patent application Ser. No. 11/494,889,filed Jul. 28, 2006, now U.S. Pat. No. 7,753,074, the disclosures ofwhich are expressly incorporated by reference herein.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to fluid control valves and,more particularly, to a mixing valve for use within a faucet.

Single-handle water faucet control valves are well known in the art andhave been offered with different mechanical structures for controllingthe available directions of travel, the ranges of motion, and the typeor style of motion for the handle. One such known style of control valveincludes a handle that is moved in a generally sideways (left-to-rightand right-to-left) direction in order to adjust the mix of hot and coldwater for a desired temperature. With this style of water faucet valvecontrol arrangement, the handle is typically moved in an upward orforward direction, away from the user, to increase the flow rate and thevolume of water delivered. The handle is typically moved in a downwardor rearward direction, toward the user, in order to reduce the flow rateand volume of water, or to completely shut off the flow of waterdelivered from the faucet.

Known single-handled control valves are often referred to as having ajoy stick control handle due to the single-handle construction and themanner in which the handle may be moved. The directions and ranges ofmotion are controlled by the internal structure of the valve mechanismand by the selection and arrangement of the component parts. It isfurther known to provide a water faucet control valve that isconstructed and arranged to independently control the temperature andthe flow rate of the water delivered to a use location by asingle-handle or control lever. Illustrative examples of single-handledfaucet control valves are described in U.S. Pat. No. 6,920,899, and U.S.patent application Ser. No. 11/444,228, filed May 31, 2006, PublicationNo. US2007/0277889, the disclosures of which are expressly incorporatedby reference herein.

One illustrative embodiment of the present invention includes a valveassembly for controlling water flow and reducing noise in a faucet, thevalve assembly including a valve body including a hot water inlet, acold water inlet, and an outlet. The valve assembly further provides alower disc supported by the valve body and including a first portcommunicating with the hot water inlet, a second port communicating withthe cold water inlet, and a third port communicating with the outlet.The illustrative embodiment further includes an upper disc having anupper surface and a lower surface, the lower surface configured tocommunicate with the lower disc to define a closed flow channel having awidth and a depth. The flow channel provides selective communicationbetween the first and second ports and the third port and the widthinversely varies with the depth in a first portion of the flow channelextending between each of the first and second ports and the third port.A stem is operably coupled to the upper surface of the upper disc andconfigured for selective pivotal movement about orthogonal axesextending within a plane parallel to the upper disc.

Another illustrative embodiment of the present invention includes avalve assembly for controlling water flow and reducing noise in afaucet, the valve assembly including a valve body including a hot waterinlet, a cold water inlet, and an outlet. Additionally, the valveassembly may include a lower disc supported by the valve body having afirst port corresponding to the hot water inlet, a second portcorresponding to the cold water inlet, and a third port corresponding tothe outlet. An upper disc having a lower surface is positioned incommunication with the lower disc and includes an inner channel edge andan outer channel edge defining a closed channel between the first,second, and third ports. The closed channel has an upstream portion anda downstream portion between each of the first and third ports and thesecond and third ports. The upstream portion includes a width and adepth varying inversely to reduce downstream flow restrictions and theclosed channel extends around a center portion of the lower surface andis configured to mix hot water from the first port and cold water fromthe second port before reaching the third port. The center portion ofthe lower surface is configured to selectively seal the first port andthe second port from the third port. The valve assembly further includesa stem operably coupled to the upper disc and configured for pivotalmovement about orthogonal axes extending within a plane parallel to theupper disc.

A further illustrative embodiment of the present invention includes avalve assembly for controlling water flow and reducing noise in afaucet, the valve assembly including a valve body including a hot waterinlet, a cold water inlet, and an outlet. A lower disc is supported bythe valve body and includes a first port corresponding to the hot waterinlet, a second port corresponding to the cold water inlet, and a thirdport corresponding to the outlet. Additionally, the valve assembly mayinclude an upper disc having an upper surface and a lower surface. Thelower surface is positioned in communication with the lower disc andincludes an inner channel edge and an outer channel edge defining aclosed flow channel having a width and a depth. The flow channelprovides selective communication between the first and second ports andthe third port and the width inversely varying with the depth in a firstportion of the flow channel between each of the first and second portsand third port. The closed peripheral channel is configured to mix hotwater from the first port and cold water from the second port beforereaching the third port. The valve assembly further includes a stemassembly including a ball supported for pivotal movement about firstaxis and a second axis orthogonal to the first axis, a stem extendingupwardly from the ball, and a knuckle extending downwardly from the balland operably coupled to the upper surface of the upper disc. The stemassembly provides pivotal movement about the first axis and the secondaxis to change a water flow rate through the first, second, and thirdports.

Additional features and advantages of the present invention will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of the illustrative embodiment exemplifying thebest mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the drawings particularly refers to theaccompanying figures in which:

FIG. 1 is a perspective view of a faucet including an illustrativeembodiment valve assembly shown in phantom;

FIG. 2 is a perspective view of the illustrative embodiment valveassembly of FIG. 1;

FIG. 3 is an exploded perspective view of the valve assembly shown inFIG. 2;

FIG. 4 is an exploded upper perspective view of internal components ofthe valve assembly shown in FIGS. 2 and 3;

FIG. 5 is an exploded bottom perspective view of internal components ofthe valve assembly shown in FIG. 4;

FIG. 6 is a bottom perspective view of the upper housing of the valveassembly shown in FIGS. 2-5;

FIG. 7 is a cross-sectional view of the upper housing shown in FIG. 6;

FIG. 8 is a bottom plan view of the upper housing shown in FIGS. 6 and7;

FIG. 9 is an exploded perspective view of the stem assembly and thecoupling member of the valve assembly shown in FIGS. 2-5;

FIG. 10 is a cross-sectional view of the valve assembly taken alonglines 10-10 of FIG. 2 with the valve assembly in the partially openorientation;

FIG. 11 is a partial top plan view of the valve assembly shown in FIG.10, with internal components of the valve assembly shown in phantom;

FIG. 12 is a cross-sectional view of the upper and lower discs of thevalve assembly taken along lines 12-12 of FIG. 10, with the valveassembly being oriented in the partially open orientation;

FIG. 13 is a cross-sectional view of the valve assembly similar to FIG.10, with the valve assembly shown in the fully-opened orientation;

FIG. 14 is a partial top plan view of the valve assembly shown in FIG.13, with internal components shown in phantom;

FIG. 15 is a cross-sectional view of the upper and lower discs of thevalve assembly taken along lines 15-15 of FIG. 13, with the valveassembly being oriented in the fully-open orientation;

FIG. 16 is a cross-sectional view of the valve assembly similar to FIG.10, with the valve assembly shown in the fully-closed orientation;

FIG. 17 is a partial top plan view of the valve assembly shown in FIG.16, with internal components shown in phantom;

FIG. 18 is a cross-sectional view of the upper and lower discs of thevalve assembly taken along lines 18-18 of FIG. 16, with the valveassembly being oriented in the fully-closed orientation;

FIG. 19 is a partial top plan view of the valve assembly shown in theprevious figures with internal components being shown in phantom, thevalve assembly being oriented to allow only cold water flow;

FIG. 20 is a cross-sectional view of the upper and lower discs of thevalve assembly shown in FIG. 19, with the valve assembly being orientedto allow only cold water flow;

FIG. 21 is a partial top plan view of the valve assembly shown in theprevious figures with internal components being shown in phantom, thevalve assembly is oriented to allow only hot water flow;

FIG. 22 is a cross-sectional view of the upper and lower discs of thevalve assembly shown in FIG. 21 with the valve assembly being orientedto allow only hot water flow;

FIG. 23 is an exploded perspective view of another illustrativeembodiment valve assembly;

FIG. 24 is a cross-sectional view of the valve assembly shown in FIG.23;

FIG. 25 is an exploded bottom perspective view of the internalcomponents of the valve assembly shown in FIGS. 23 and 24;

FIG. 26 is an exploded upper assembly view of the internal components ofthe valve assembly shown in FIGS. 23-25;

FIG. 27 is a partial perspective view of a further illustrativeembodiment valve assembly, with the valve body and the bonnet nutremoved for clarity;

FIG. 28 is an exploded perspective view of the valve assembly of FIG.27;

FIG. 29 is a top plan view of the valve assembly of FIG. 27, with thetemperature limiting member shown in a low limit position and the stemshown in a fully-closed position;

FIG. 30 is a perspective view of the valve assembly of FIG. 27, with theupper housing removed for clarity;

FIG. 31 is a cross-sectional view taken along line 31-31 of FIG. 29;

FIG. 32 is a cross-sectional view taken along line 32-32 of FIG. 29;

FIG. 33 is a bottom plan view of the upper housing of the valve assemblyof FIG. 27;

FIG. 34 is a bottom perspective view of the temperature limiting memberof the valve assembly of FIG. 27;

FIG. 35A is a side elevational view of the valve assembly of FIG. 29,with the temperature limiting member shown in a low limit position andthe stem shown in a fully-closed position;

FIG. 35B is a side elevational view similar to FIG. 35A, with the stemshown in an open hot limit position;

FIG. 35C is a side elevational view similar to FIG. 35A, with the stemshown in an open cold limit position;

FIG. 36 is a top plan view of the valve assembly of FIG. 27, with thetemperature limiting member shown in a high limit position and the stemshown in a fully-closed position;

FIG. 37 is a perspective view of the valve assembly of FIG. 27, with theupper housing removed for clarity;

FIG. 38A is a side elevational view of the valve assembly of FIG. 36,with the temperature limiting member shown in a high limit position andthe stem shown in a fully-closed position;

FIG. 38B is a side elevational view similar to FIG. 38A, with the stemshown in an open mixed water position;

FIG. 38C is a side elevational view similar to FIG. 38A, with the stemshown in an open hot limit position;

FIG. 38D is a side elevational view similar to FIG. 38A, with the stemshown in an open cold limit position;

FIG. 39 is a top plan view of a further embodiment of the upper disc andthe lower disc of the valve assembly of FIG. 3;

FIG. 40 is a cross-sectional view of the upper disc and lower disc takenalong line 40-40 of FIG. 39;

FIG. 41 is a cross-sectional view of the upper disc and lower disc takenalong line 41-41 of FIG. 39;

FIG. 42 is a cross-sectional view of the upper disc and lower disc takenalong line 42-42 of FIG. 39;

FIG. 43 is an exploded perspective view of a lower surface of the upperdisc and an upper surface of the lower disc of FIG. 39;

FIG. 44 is a bottom perspective view of the topography of the lowersurface of the upper disc of FIG. 43;

FIG. 45 is a front perspective view of the upper surface of the lowerdisc of FIG. 43;

FIG. 46 is a cross-sectional view of the upper disc and the lower disctaken along line 46-46 of FIG. 39;

FIG. 47 is a cross-sectional view of the upper disc and the lower disctaken along line 47-47 of FIG. 39;

FIG. 48 is a cross-sectional view of the upper disc and the lower disctaken along line 48-48 of FIG. 39;

FIG. 49 is a cross-sectional view of the upper disc and the lower disctaken along line 49-49 of FIG. 39; and

FIG. 50 is a graph of a dimensional profile of a flow channel defined bythe upper disc and the lower disc of FIG. 39.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to beexhaustive or to limit the invention to precise forms disclosed. Rather,the embodiment selected for description have been chosen to enable oneskilled in the art to practice the invention. Although the disclosure isdescribed in connection with water, it should be understood thatadditional types of fluids may be substituted therefor.

Referring initially to FIG. 1, a faucet assembly 10, having a hot watersupply conduit 20 and a cold water supply conduit 22, is shown. Faucetassembly 10 includes a delivery spout 16, an aerator 18, a base 12, ahandle 14, and a valve assembly 24. Valve assembly 24 includes a stem 26that may be actuated by handle 14 to selectively allow variabletemperature and flow rate of water to be supplied to spout 16 fromsupply conduits 20 and 22.

Referring now to FIG. 2, valve assembly 24 is shown. Valve assembly 24includes valve body 34 and bonnet nut 28. In this embodiment, valve body34 and bonnet nut 28 are constructed of brass, however any suitablematerial may be used. Valve body 34 includes outlet bore 36 which may beoperably coupled to an outlet supply line which, in turn, may be coupledto a spout 16, such as the one shown in FIG. 1, or any other suitablefluid delivery device, such as a hand sprayer. Bonnet nut 28 includesinternal threads 39 that correspond to external threads 37 of valve body34 (FIG. 10). Bonnet nut 28 also includes grooves 30 positioned toaccept a wrench (not shown) to secure bonnet nut 28 to valve body 34.Bonnet nut 28 further includes a central aperture 32 into which an upperhousing 38 extends. Stem 26 extends through aperture 46 of upper housing38. In this embodiment, aperture 46 is substantially diamond-shaped tolimit the movement of stem 26, however any suitably shaped aperture maybe used.

Referring now to FIGS. 3-9, the internal components of valve assembly 24are shown. Valve assembly 24 includes valve body 34, lower housing 80,lower disc 72, upper disc 68, carrier 62, coupling member 50, stemassembly 23, upper housing 38, and bonnet nut 28. The exterior portionof upper housing 38 includes a shoulder portion 48, a flange 40,extensions 44, and tabs 42. Flange 40 extends circumferentially aroundportions of upper housing 38, and is positioned between bonnet nut 28and valve body 34 when bonnet nut 28 is threaded onto valve assembly 34.As such, bonnet nut 28 provides a compressive force on flange 40 andupper housing 38. Flange 40 also provides a barrier between bonnet nut28 and valve body 34 to prevent corrosion and seizing therebetween. Incertain embodiments, shoulder portion 48 may be configured to contactinterior ridge 31 of bonnet nut 28 to compress upper housing 38 whenvalve assembly 24 is assembled. Illustratively, upper housing 38 isconstructed of plastic, however any other suitable materials may be usedto construct the components.

Valve assembly 24 also includes stem assembly 23 which includes ball 25,stem 26, lateral extensions 27 a, 27 b, and longitudinal extension orknuckle 29. In the illustrative embodiment, a first angle α definedbetween the longitudinal axis of stem 26 and an axis defined byextension 27 a is greater than ninety degrees, and a second angle βdefined between the longitudinal axis of stem 26 and the axis defined byextension 27 b is less than ninety degrees (FIG. 10). However, it shouldbe appreciated that stem 26 may be positioned at any suitable anglerelative to extensions 27 a and 27 b. Stem assembly 23 is positionedbetween upper housing 38 and coupling member 50 so that stem 26 extendsthrough aperture 46 in upper housing 38 and ball 25 is positioned ininterior cavity 53 of upper housing 38 (FIG. 6). Referring now to FIGS.6-8, upper housing 38 includes interior cavity 53, opposing arcuateflexible ribs 55, and opposing relief portions 57. Arcuate flexible ribs55 extend from interior cavity 53 and provide a compressive force onball 25 when valve assembly 24 is fully assembled.

Referring now to FIGS. 3 and 9, coupling member 50 includescircumferentially spaced projections 52 and apertures 60 positionedradially outwardly from cavity 54. Aperture 51 is positioned at thebottom of cavity 54 which is formed by arcuate surface 59.Illustratively, aperture 51 is of a substantially triangular shape.Apertures 60 are positioned to accept tabs 42 of upper housing 38 tocouple stem assembly 23 between upper housing 38 and coupling member 50.Tabs 42 each include a latch or lip 43 configured to cooperate with anotch 41 of each aperture 60 for locking engagement therebetween (FIGS.6 and 10). Projections 52 are positioned to secure coupling member 50 tolower housing 80 (as shown in FIG. 3), which is discussed below.

Coupling member 50 also includes a first pair of tabs 56 and a secondpair of tabs 58 that extend upwardly from cavity 54. When assembled,ball 25 is positioned in cavity 54 and extensions 27 a and 27 b arepositioned between first pair of tabs 56 and second pair of tabs 58,respectively, as shown in FIG. 9. First and second pairs of tabs 56 and58 are positioned adjacent to extensions 27 a and 27 b of stem assembly23 and define opposing continuous glide surfaces 61 a and 61 b along therange of motion of ball 25 of stem assembly 23. In operation, extensions27 a and 27 b glide along the surfaces 61 a and 61 b, respectively, oftabs 56 and 58 during movement of stem 26 to operate valve assembly 24.

Referring now to FIG. 6-9, when assembled, relief portions 57 of upperhousing 38 accept first and second pairs of tabs 56 and 58 of couplingnumber 50. As shown in FIG. 3, stem assembly 23 is positioned betweenupper housing 38 and coupling number 50. As discussed above, extensions27 a and 27 b of stem assembly 23 are positioned between first pair oftabs 56 and second pair of tabs 58 of coupling member 50. Stem 26extends through aperture 46 in upper housing 38. First pair of tabs 56and second pair of tabs 58 are positioned in relief portions 57 of upperhousing 38. An upper portion of ball 25 of stem assembly 23 is contactedby arcuate flexible ribs 55 of upper housing 38, and a lower portion ofball 25 is contacted by arcuate surface 59 of coupling member 50. Tabs42 interact or “snap fit” within openings 60 in coupling member 50 tosecure stem assembly 23 between upper housing 38 and coupling member 50.Longitudinal projection 29 extends through aperture 51 in couplingnumber 50.

Referring now to FIGS. 3-5, longitudinal extension 29 of stem assembly23 extends into recess or aperture 64 of carrier 62. Carrier 62 includesplurality of projections 65, plurality of arcuate openings 67, andgroove 63 configured to accept a conventional O-ring 66. Plurality ofprojections 65 of carrier 62 interact with depressions 69 in the uppersurface 68 a of upper disc 68. O-ring 66 contacts the upper surface 68 aof upper disc 68 and forms a circumferential seal between carrier 62 andthe upper surface 68 a of upper disc 68. Upper disc 68 includes anaperture 70 extending therethrough to provide fluid communicationbetween a lower surface 68 b of upper disc 68 and the lower surface 62 bof carrier 62.

As shown in FIG. 3, upper disc 68 is positioned on top of lower disc 72in valve assembly 24. The lower surface 68 b of upper disc 68 is shownin more detail in FIG. 5. Upper disc 68 is positioned on top of lowerdisc 72 in valve assembly 24 to control the mixing of hot and cold waterand the flowrate of water through valve assembly 24. Upper disc 72includes a pair of notches 74 configured to interact with portions 86 oflower housing 80 to orient and prevent rotation of upper disc 72relative to lower housing 80. In this embodiment, both upper and lowerdiscs 68 and 72 are constructed of a ceramic material, however anysuitable material may be used, such as stainless steel.

Referring further to FIGS. 4 and 5, the upper and lower surfaces ofcarrier 62, upper disc 68, lower disc 72, lower housing 80 and valvebody 34 are shown. Lower disc 72 includes hot and cold water inlet ports76 a and 76 b and outlet port 78. The lower surface 68 b of upper disc68 includes a circumferentially extending channel 77 divided between acentral portion 73 and an annular ridge or lip 79. Central portion 73includes V-shaped section 71 conforming to a projection 75 of annularlip 79. Channel 77 and central portion 73 provide selectivecommunication between hot and cold water inlet ports 76 a and 76 b andoutlet port 78 when upper disc 68 is moved relative to lower disc 72.The interaction between upper disc 68 and lower disc 72 during operationof valve assembly 24 is described in more detail in connection withFIGS. 10-22. In the illustrative embodiment, carrier 62 and upper disc68 have substantially smaller diameters than lower disc 72 and lowerhousing 80 to enable upper disc 68 to be moved relative to lower disc72, as shown in FIG. 10.

Referring now to FIGS. 3 and 4, lower disc 72 is positioned in lowerhousing 80. Opening 81 of lower housing 80 is sized to allow seals 90,which are positioned in hot and cold water inlet bores 91 a and 91 b andoutlet bore 95, to seal against the lower surface 72 b of lower disc 72.Seals 90 a and 90 b form a seal around hot and cold water inlet ports 76a and 76 b on lower surface 72 b of lower disc 72, and seal 90 c forms aseal around outlet port 78 on the lower surface 72 b of lower disc 72.Collectively, seals 90 form a single sealing surface between valve body34 and internal components of valve assembly 24. Hot and cold inletbores 91 a and 91 b are illustratively connected to hot and cold watersupply conduits 20 and 22, respectively. Outlet bore 95 may be connectedto an outlet supply line to, for example, spout 16 of faucet 10, such asthe one shown in FIG. 1. Hot and cold water inlet ports 76 a and 76 band outlet port 78 of lower disc 72 are positioned directly above, andin fluid communication with, hot and cold water inlet bores 91 a and 91b and outlet bore 95 of valve body 34, respectively.

Referring now to FIGS. 3-5, lower housing 80 includes a pair of upwardlyextending extensions 82 including apertures 84 configured to acceptprojections 52 of coupling member 50 to secure coupling member 50 tolower housing 80. Lower housing 80 also includes a pair of lowerprojections 88 configured to be positioned in bores 93 in the lowerinterior surface of valve body 34 to prevent rotation of lower housing80 relative to valve body 34. As illustrated, seals 90 a, 90 b, and 90 care positioned in bores 91 a, 91 b, and 95 in the lower interior surfaceof valve assembly 90 to prevent water leakage between bores 91 a, 91 b,and 95 in valve body 34 and the lower surface 72 b of lower disc 72. Inthis illustrative embodiment, valves 90 are constructed of rubber andprovide a biasing force between the lower surface of valve body 34 andlower disc 72. Seals 90 may be of the type detailed on U.S. patentapplication Ser. No. 11/444,228, filed May 31, 2006, which has beenexpressly incorporated by reference herein. Valve body 34 includes apair of notches 35 configured to accept tabs 44 extending from upperhousing 38 to prevent rotation of upper housing 38 relative to valvebody 34. Valve body 34 also includes external threads 37 configured tointeract with internal threads 39 (FIG. 10) on the interior surface ofbonnet nut 28 to secure bonnet nut 28 to valve body 34.

Referring further to FIG. 5, when valve assembly 24 is coupled to hotand cold water supply conduits 20 and 22, a pressure reducinghydrobalance is created between carrier 62 and upper disc 68. Aperture70 in upper disc 68 allows water from channel 77 to flow between carrier62 and the upper surface 68 a of upper disc 68. Openings 67 of carrier62 may also be supplied with water supplied from aperture 70. In theillustrative embodiment, the area of upper surface 68 a of upper disc 68defined within O-ring 66, which is positioned in groove 63 of carrier62, is greater than the collective cross-sectional area of seals 90 aand 90 b, which are positioned between the lower surface of lower disc72 and valve body 34. In other words, the water pressure between carrier62 and upper disc 68 has a greater surface area on which to act thanthat of water pressure acting on seals 90 a and 90 b. Therefore, thewater pressure creates a net downward force on the upper surface 68 a ofupper disc 68 to minimize any leakage between upper disc 68 and lowerdisc 72.

Referring now to FIG. 10, a cross-sectional view of valve assembly 24 isshown. As discussed above, interior ridge 31 of bonnet nut 28 contactsshoulder portion 48 of 48 of upper housing 38 to provide a compressiveforce on upper housing 38. Additionally, flange 40 is positioned betweenbonnet nut 28 and valve body 34 to prevent corrosion and provide abiasing force between bonnet nut 28 and valve body 34. Tabs 42 of upperhousing 38 interact with notches 41 of aperture 60 in coupling member 50to couple coupling member 50 to upper housing 38. Longitudinal extension29 extends through opening 53 in coupling number 50 into aperture 64 incarrier 62. Projections 65 extend into depressions 69 in the uppersurface of upper disc 68. As discussed above, the diameters of carrier62 and upper disc 68 are substantially smaller than the diameter oflower disc 72.

As further shown in FIG. 10, carrier 62 and lower disc 68 are moved bylongitudinal extension 29 of stem assembly 23 to selectively adjust thetemperature and the flowrate of water supplied by valve assembly 24. Asdiscussed above, one of the seals 90 c is positioned in outlet bore 95of valve body 34. Outlet bore 95 opens into radially extending outletbore 36 in valve body 34. As detailed herein, seal 90 c directlycontacts the lower surface of lower disc 72 around outlet port 78.Outlet bore 36 is also in communication with axially extending outletbore 92 of valve body 34. Bore 92 may be coupled to spout 16 or to anaccessory supply line which may be used for a hand sprayer or any othersuitable fluid delivery device.

Referring now to FIGS. 10-12, valve assembly 24 is shown with stem 26pivoted or oriented to place the internal components of valve assembly24 in the partially open position. When stem 26 is in this orientation,an equal amount of hot and cold water is allowed to pass through hot andcold water inlets 76 a and 76 b to outlet port 78. Referringspecifically to FIGS. 11 and 12, in this orientation, channel 77 and thelower surface 68 b of upper disc 68 are positioned over a small portionof each of the hot and cold water inlet ports 76 a and 76 b. Centralportion 73 of upper disc 68 is covering a significant portion of inletports 76 a and 76 b. As water enters channel 77 through inlet hot andcold water inlet ports 76 a and 76 b, it fills channel 77, mixes tocreate “warm” water, and exits through outlet 78, which is substantiallyopen to channel 77. The “warm” water then moves through outlet port 78and seal 90 to outlet bore 95 and spout 16 as shown in FIG. 1.

Referring now to FIGS. 13-15, stem 26 has been pivoted forward to adifferent orientation such that inlet ports 76 a and 76 b aresubstantially uncovered or unblocked by central portion 73 of upper disc68. A greater amount of hot and cold water is allowed to fill channel77, mix to create “warm” water, and exit through outlet port 78. Thewater then exits valve assembly 24 through outlet bore 95 as discussedabove. In each of these two positions, hot water and cold water frominlet ports 76 a and 76 b are mixed in channel 77 to produced warmwater, which will exit channel 77 through outlet port 78. In theembodiment shown in FIGS. 10-12, a lower flowrate or amount of waterwill exit valve assembly 24. In FIGS. 13-15, a “full flow,” or maximumflowrate of water, will exit valve assembly 24.

Referring now to FIGS. 16-18, stem 26 is shown pivoted in a rearwarddirection to the fully or completely closed orientation. In thisorientation, valve assembly 24 will be closed (i.e., no water will flowthrough valve assembly 24). Scallop or convergence 46 a of aperture 46(FIG. 2) cooperates with longitudinal extension 29 of stem assembly 23to provide a detent of stem assembly 23 when in the completely closed orzero position. As shown in FIGS. 16 and 18, central portion 73 of upperdisc 68 completely covers or blocks hot and cold water inlet ports 76 aand 76 b to prevent water from filling channel 77 and exiting throughoutlet port 78. Even if water were to leak through either inlet ports 76a and 76 b to channel 77, the water would exit channel 77 through outlet78 to create a drip or small stream, for example, through the spout ofthe faucet assembly including valve assembly 24. In this manner, channel77 prevents water leaks in the valve assembly 24 from leaking throughthe valve assembly to the faucet base 12 or under the faucet 10, whichmay cause corrosion around the faucet base 12 or handle 14 of the faucet10. If any leakage were to occur in valve assembly 24 as a result ofdamage to discs 68 and 72 adjacent ports 76 a, 76 b, 78, the waterleaked would exit valve assembly 24 through outlet bore 95 and anyattached spout 16 or accessory rather than around the base 12 of thefaucet 10.

FIGS. 19 and 20 illustrate the stem 26 orientation and the correspondingposition of upper disc 68 when the operator desires only cold water fromvalve assembly 24. As shown, when stem 26 is positioned in thisorientation, central portion 73 of upper disc 68 completely covers orblocks hot water inlet port 76 a and completely uncovers or unblocks thecold water inlet port 76 b, allowing the water from the uncovered port76 b to flow through channel 77 to outlet port 78. Conversely, in FIGS.22 and 23, the stem 26 orientation shown opens the opposite port 76 a(i.e., allows the user to select completely hot water flow). As shown,in this orientation, central portion 73 of upper disc 68 completelycovers or blocks the previously uncovered cold water inlet port 76 b andcompletely opens the previously covered hot water inlet port 76 a toallow hot water to fill channel 77 and exit through outlet port 78.

Another illustrative embodiment of valve assembly 24 is shown in FIGS.23-26. Referring now to FIGS. 23 and 24, valve assembly 110 includesbonnet nut 112, upper housing 116, stem assembly 120, coupling member130, carrier 132, upper disc 138, lower disc 144, upper seal 150, lowerhousing 152, lower seal 154, and valve body 158. Valve assembly 110 issimilar to valve assembly 24 shown in the previous embodiment, howevervalve assembly 110 includes two opposing sealing surfaces instead of thesingle sealing surface defined by seals 90 in valve assembly 24. In thisembodiment, carrier 132 includes interior wall 134 and downwardextending projection 136, which interacts with notch 142 in upper disc138. Upper disc 138 also includes opening 140 which is configured toaccept interior wall 134 of carrier 132. Longitudinal extension 129 ofstem assembly 120 extends through coupling member 130 and into interiorwall 134 of carrier 132 to actuate carrier 132 and upper disc 138.

Referring now to FIGS. 25 and 26, lower disc 144 includes hot and coldwater inlet ports 146 a and 146 b and outlet port 148. The lower surfaceof lower disc 144 includes channel 145 extending around inlet ports 146a and 146 b and outlet port 148. Seal 150 is positioned in channel 145and corresponds to channel 151 in the upper surface of lower housing 152as shown in FIG. 26. The lower housing 152 includes channel 153extending around inlet apertures 151 and outlet aperture 155. Channel153 corresponds to seal 154 which is positioned in channel 153 toprovide a seal against the interior lower surface of valve body 158.Valve body 158 includes inlet bores 160 and outlet bore 162 which areconfigured to couple to hot and cold water inlet supply lines and anoutlet supply line. In this embodiment, valve assembly 110 includes twosealing surfaces 150 and 154 compared to the single layer of sealingsurfaces formed by seals 90 between lower disc 72 and the interior lowersurface of valve body 34 of valve assembly 24 shown in FIGS. 2-22.

A further illustrative embodiment valve assembly 210 is shown in FIGS.27-38D. While not shown, bonnet nut 28 and valve body 34 similar tothose detailed above may be utilized to receive the internal valvecomponents of valve assembly 210. Valve assembly 210 includes upperhousing 216, temperature limiting member 218, stem assembly 220,coupling member 230, carrier 232, upper disc 238, lower disc 244, upperseal 250, lower housing 252, and lower seal 254. Carrier 232, upper disc238, and lower disc 244, may be similar to carrier 132, upper disc 138,and lower disc 144, as detailed above. Likewise, seals 250 and 254 maybe similar to seals 150 and 154, as detailed above in connection withvalve assembly 110.

Furthermore, as with valve assembly 110, upper disc 238 may includeopening 140 which is configured to receive interior wall 134 of carrier232. Also, lower disc 244 includes hot and cold water inlet ports 146 aand 146 b and outlet port 148.

As shown in FIG. 28, stem assembly 220 includes a ball 225 whichreceives a stem 226. As shown in FIGS. 28 and 31, stem 226 may besubstantially L-shaped and include upwardly extending leg 228 a andlaterally extending leg 228 b. Ball 225 may be molded from athermoplastic material over a portion of stem 226, such that leg 228 bdefines a support for a lateral extension 227. A longitudinal extensionor knuckle 229 extends downwardly from the ball 225 generally oppositeleg 228 a of the stem 226. In a manner similar to that detailed above,ball 225 transmits motion of stem 226 to upper disc 238 throughextension 229 and carrier 232.

With reference to FIGS. 28 and 32, coupling member 230 includesdiametrically opposed tabs 256 extending downwardly from a circular base258. Tabs 256 are configured to be received within notches 260 formedwithin lower housing 252 to facilitate proper angular orientationbetween coupling member 230 and lower housing 252 and prevent relativerotation therebetween. A pair of diametrically opposed notches 262 areformed within an outer edge of base 258 and are configured to receivelocking extensions or loops 264 of upper housing 216. A pair ofdiametrically opposed recesses 266 extend downwardly from an uppersurface 268 of base 258 and are configured to receive tabs 270 of upperhousing 216, thereby facilitating proper angular orientation betweenupper housing 216 and coupling member 230. An upwardly extendingcylindrical wall 272 is coupled to base 258 and forms a cavity 274having an arcuate surface 276. An opening 278 formed within wall 272 isconfigured to receive extension 227 of stem assembly 220. Ball 225 ofstem assembly 220 is configured to contact arcuate surface 276 ofcoupling member 230 in a manner similar to that detailed above withrespect to valve assembly 24. Aperture 280 is positioned at the bottomof cavity 224 and is configured to receive extension 229 of stemassembly 220 which, in turn, engages carrier 232.

With reference to FIGS. 28 and 34, temperature limiting member 218 isreceived intermediate coupling member 230 and upper housing 216.Temperature limiting member 218 includes a cylindrical body portion 282and a pair of downwardly extending biasing members, illustrativelyflexible arms 284. The flexible arms 284 have a lower contact surface286 configured to slide along a glide surface defined by the uppersurface 268 of base 258 of coupling member 230. Body portion 282includes a cylindrical wall 286 having an upper surface 288 supporting aplurality of indexing members, illustratively teeth 290. An indicator292 extends upwardly above the teeth 290. Wall 286 of cylindrical bodyportion 282 includes a downwardly facing inclined surface 294. Asexplained herein, inclined surface 294 cooperates with lateral extension227 of stem assembly 220 to limit the lateral pivoting motion of stem226 and extension 229 (i.e., relative to inlet ports 146 a and 146 b),and hence the maximum allowable temperature of water flowing through thevalve assembly 210.

Referring now to FIGS. 28, 29, 31, and 33, upper housing 216 includes acylindrical outer wall 296 and a cylindrical inner wall 298. Walls 296and 298 are concentric, thereby defining a channel 300 therebetween. Anupper portion of wall 286 of temperature limiting member 218 issupported for movement within channel 300. A rim 302 extends radiallyoutwardly from outer wall 296. Downwardly extending loops 264 aresupported by rim 302 and are configured to cooperate with notches 262formed in the coupling member 230, and with latches or tabs 304 formedwithin lower housing 252 (FIG. 28). More particularly, the loops 264 arereceived within recesses 306 surrounding the latches 304. Each latch 304includes an inclined or ramp surface 308 and a retaining surface 310configured to cooperate with an inner surface 312 of the respective loop264. Outer wall 296 includes a receiving channel or slot 314 configuredto receive the lateral extension 227 of the stem assembly 220.

As shown in FIGS. 31 and 33, a plurality of indexing members,illustratively teeth 316, extend downwardly from an upper member 318 ofupper housing 216 and are configured to cooperate with teeth 290 oftemperature limit device 218. An arcuate slot 320 is formed within uppermember 318 of upper housing 216 and is configured to receive indicator292. An opening 322 similar to opening 46 of previously described upperhousing member 38 is formed within upper member 318.

Pivoting movement of stem assembly 220 about axis 324 of lateralextension 227 controls the flow rate of water, while pivoting movementof stem assembly 220 about an axis 326, perpendicular to axis 324 oflateral extension 227 and stem 226, controls the temperature of watersupplied by valve assembly 210. The inclined surface 294 of thetemperature limiting member 218 controls the amount of pivoting movementof the stem assembly 220 about axis 326. As further detailed below,rotation of the temperature limiting member 218 about its center axis328 limits the motion permitted of stem assembly 220 about axis 328.

As detailed herein, stem assembly 220 includes ball 225 that transmitsstem motion to upper disc 238 through extension 229. Ball 225 allowsspherical rotation, while preventing lateral motion. Since valveassembly 210 only requires two degrees of freedom (temperature andvolume), rotation about stem assembly 220 is prevented by operation oflateral extension 227 coupled to ball 225 that rides in the slot 314 incooperating upper housing 216.

Lateral extension 227 has two motions in slot 314. The first motion is apivot motion about its own axis 324. The second motion is a pivot motionabout axis 326, which is substantially vertical, within slot 314, andwhich has a constant radius from the center of the ball 225. Throughorientation of slot 314, these two motions may correspond directly totemperature and volume motion of valve disc 218.

While the pivoting movement of stem assembly 220 of valve assembly 210is similar to the pivoting movement of stem assembly 120 of valveassembly 110 (FIG. 23), the extension 227 of stem assembly 220 is offsetby 90° from extensions 27 of stem assembly 120. If the extension 227 islocated in a side-to-side orientation relative to inlet ports 146 a and146 b (FIG. 28), as opposed to a front-to-back orientation relative toinlet ports 146 a and 146 b and outlet port 148 (FIG. 23), thetemperature will be directly related to the motion of the extension 227in the slot 314. The flow rate control motion will translate to therotation of the extension 227 about its own axis 324. As such, to limitthe maximum temperature, the travel of extension 227 within the slot 314is reduced or limited. The limiting member 218 includes inclined surface294 that engages extension 227 on the ball 225. As the temperaturelimiting member 218 is rotated about axis 328 of the valve assembly 210,the point of inclined surface 294 that is engageable with the extension227 is set at different heights and, thereby, limits the travel of theextension 227 in the slot 314. This, in turn, limits the motion of upperdisc 238 relative to lower disc 244, including hot water inlet put 146a.

Teeth 290 of temperature limiting member 218 engage with correspondingteeth 316 on the upper housing 216. This engagement keeps thetemperature limit device 218 from slipping under load and providesdetents to indicate discrete adjustment positions. Flex arms 284 oftemperature limiting member 218 provide a preload on the engaged teeth290, 316 and to prevent temperature limiting member 218 from slippingdue to vibration. This preload also gives the adjuster a tactilefeedback to prevent over-correction of a temperature limiting member218. The tab or indicator 292 of the temperature limiting member 218also protrudes through the slot 320 of upper housing 216 and provides avisual indication to the user of the temperature setting. Marks may beprovided on the upper housing 216 to provide reference points of therelative position of indicator 292 within slot 320.

With further reference now to FIGS. 29, 30, and 35A-35C, valve assembly210 is illustrated with the temperature limiting member 218 positionedin a low limit position “L”. Indicator 292 in FIG. 29 shows the lowlimit position within slot 320 of upper housing 216. In FIGS. 29, 30,and 35A, stem assembly 220 is in a fully-closed position. As detailedabove, this means that the upper disc 238 engages the lower disc 244 sothat water does not flow from either hot or cold inlet ports 146 a and146 b to outlet port 148. As shown in FIG. 35B, valve assembly 220 ismoved to an open hot limit position. Moreover, stem assembly 220 ispivoted about axis 324 to an open flow position and also pivoted aboutaxis 326 to the temperature limit position as defined by the inclinedsurface 294 of temperature limiting device 218. In other words, stemassembly 220 is pivoted as far as possible to its hot, or left, positionabout axis 326 due to engagement of the extension 227 and inclinedsurface 294 of temperature limiting member 218. FIG. 35C illustrates thevalve assembly 210 in an open cold limit position, where the stemassembly 220 is pivoted as far as possible to its cold, or right,position about axis 326 due to engagement between the extension 227 andbase 258.

FIGS. 36-38D show valve assembly 210 with temperature limiting member218 in a high limit position “H”. Indicator 292 in FIG. 36 shows thehigh limit position within slot 320 of upper housing 216. In otherwords, temperature limiting member 218 has been rotatedcounter-clockwise by approximately 90 degrees from the position shown inFIGS. 29, 30, and 35A-35C. Such rotation is accomplished by pushing downon temperature limiting member 218 against the bias of arms 284, suchthat teeth 290 disengage from teeth 316 of upper housing 216.Temperature limiting member 218 is then free to be rotated by glidingsurfaces 286 of arms 284 against slide surface 268 of coupling member230, such that indicator 292 moves within arcuate slot 320.

FIGS. 36-38A illustrate stem assembly 220 in a fully-closed position.FIG. 38B shows stem assembly 220 in a mixed temperature position wherewater flows from both hot and cold inlet ports 146 a and 146 b to outletport 148 of upper disc 244. FIG. 38C illustrates stem assembly 220 in anopen hot limit position where maximum flow is permitted through hotwater port to outlet 148. As clearly illustrated by comparing FIG. 38Cto FIG. 35B, the stem in FIG. 38C has rotated further about axis 326toward the hot water position, or to the left. This is because the pointof contact between extension 227 and inclined surface 294 is higher inFIG. 38C than in FIG. 35B. As detailed above, in FIGS. 36-38Dtemperature limiting member 218 has been rotated counter-clockwiseapproximately 90° from the position shown in FIGS. 29, 30, and 35A-35C.FIG. 38D illustrates stem assembly 220 in an open cold limit positionwhich is substantially the same as that position illustrated in FIG.35C.

FIGS. 39-49 show an alternative embodiment of the present disclosureincluding valve assembly 210′ having an upper disc 338 sealingly coupledto a lower disc 344. Valve assembly 210′ may include many of the similarfeatures detailed above, wherein like reference numbers identify similarcomponents. While not shown, valve assembly 210′ may further includeupper housing 216, temperature limiting member 218, stem assembly 220,coupling member 230, carrier 232, upper seal 250, lower housing 252, andlower seal 254, as detailed above (FIGS. 27-38D). Valve body 34 may befurther utilized to receive the internal valve components of valveassembly 210′.

Referring to FIGS. 43 and 45, lower disc 344 has an upper surface 346and a lower surface 348. Lower disc 344 includes hot and cold waterinlet ports 146 a and 146 b and outlet port 148 and may have othercharacteristics and features similar to lower discs 144 and 244,detailed above. Hot and cold water inlet ports 146 a and 146 b andoutlet port 148 of lower disc 344 are positioned directly above, and influid communication with, hot and cold water inlet bores 91 a and 91 band outlet bore 95 of valve body 34, respectively. As with lower disc244, lower surface 348 of lower disc 344 may cooperate with seal 250 andthe upper surface of lower housing 252 (FIG. 28) when positioned withinvalve assembly 210.

As is shown in FIGS. 39, 41, and 43, upper disc 338 is positioned abovelower disc 344. More particularly, a lower surface 342 of upper disc 338is configured to sealingly communicate with upper surface 346 of lowerdisc 344 to define a closed flow channel 360. Upper disc 338 may bemoved along lower disc 344 by stem assembly 220. Stem assembly 220 andcarrier 232 (FIG. 28) engage with an opening 340 in an upper surface 339of upper disc 338 in order to selectively adjust the of position upperdisc 338 relative to hot water inlet port 146 a, cold water inlet port146 b, and outlet port 148 in the manner further detailed herein.

Referring to FIG. 44, lower surface 342 of upper disc 338 includes acenter portion 356 and a perimeter portion 358 separated by a recessedportion 350. Center portion 356 is configured to selectively seal hotand cold water inlet ports 146 a and 146 b from outlet port 148 whenupper disc 338 is in communication with lower disc 344. Recessed portion350 and center portion 356 define closed flow channel 360 between inletports 146 a and 146 b and outlet port 148 when upper disc 338 is incommunication with lower disc 344. Specifically, perimeter portion 358defines an outer channel edge of the flow channel 360 and center portion356 defines an inner channel edge of the flow channel 360. Closed flowchannel 360 extends around center portion 356 and is configured toselectively mix water from hot and cold water inlet ports 146 a and 146b before the water reaches outlet port 148.

With reference to FIGS. 39, 43, and 44, the flow channel 360 includes anupstream, or first, portion 362 and a downstream, or second, portion364. Illustratively, upstream portion 362 extends proximate hot and coldwater inlet ports 146 a and 146 b. More particularly, upstream portion362 may encompass corresponding locations of channel 360 extending alonghot and cold water inlet ports 146 a and 146 b, such that upstreamportion 362 extends between each of the inlet ports 146 a and 146 b. Asshown in FIG. 39, upstream portion 362 a extends along positions A, B,C, D, E, and F proximate the hot water inlet port 146 a and upstreamportion 362 b may further encompass corresponding locations of channel360 along the opposite side of upper disc 338. Downstream portion 364 ofchannel 360 extends from upstream portion 362 and around outlet port148. Illustratively, downstream portion 364 b extends along positions G,H, I, J, K, and L of channel 360, as shown in FIG. 39. Similarly,downstream portion 364 a may further encompass corresponding locationsof channel 360 along the opposite side of outlet port 148.

FIGS. 40-42 and 46-49 are cross-sectional views showing channel 360having a width (w), a depth (d), and a cross-sectional area (A)corresponding to each of the positions A-L referenced in FIG. 39. FIG.50 illustrates dimensions for width (w), depth (d), and area (A) foreach position A-L. As shown, in upstream portion 362, the width (w) ofchannel 360 illustratively varies inversely with the depth (d). As such,there may be a substantially constant flow area (A) in upstream portion362 of channel 360 in order to reduce downstream flow restrictions.Illustratively, the width (w) may increase in downstream portion 364 ofchannel 360 while the depth (d) remains the same. As a result, thecross-sectional flow area (A) of channel 360 in downstream portion 364may increase as water enters downstream portion 364 and flows towardoutlet port 148 (i.e., position L) to exit channel 360.

In operation, water enters channel 360 in upstream portion 362,specifically, position A (FIG. 47), through hot water inlet port 146 aand/or cold water inlet port 146 b. At position A, the width (w) ofchannel 360 is illustratively 0.099 inches and the depth (d) isillustratively 0.113 inches. Illustratively, the width (w) of channel360 increases to 0.149 inches as water flows toward position B (FIG.46). However, to maintain the substantially constant flow area (A) ofapproximately 0.01 0.04 inches in upstream portion 362, the depth (d) atposition B decreases to 0.085 inches. Water continues to flow towardposition C (FIG. 42), where the width (w) of channel 360 furtherillustratively increases to 0.174 inches. Again, to maintain thesubstantially constant flow area (A) of approximately 0.01-0.04 inches,the depth (d) at position C illustratively inversely decreases to 0.068inches in response to the change in the corresponding width (w).Illustratively, at position D (FIG. 48), the width (w) of channel 360begins to decrease to 0.171 inches and inversely, the depth (d)increases to 0.082 inches. As the width (w) of upstream portion 362 ofchannel 360 continues to decrease to 0.152 inches at position E (FIG.49), the corresponding depth (d) increases to 0.106 inches, in order tomaintain the substantially constant flow area (A) of 0.01-0.04 inches.Position F (FIG. 41) is illustratively 0.133 inches wide and 0.122inches deep.

After passing position F, water begins to flow into downstream portion364 at position G (FIG. 49). Illustratively, downstream portion 364 doesnot have a substantially constant flow area (A) and the width (w) ofchannel 360 does not vary inversely with the depth (d). Rather, thedepth (d) remains constant while the width (w) increases in downstreamportion 364 such that the flow area (A) increases. For example, as isshown in FIG. 50, at position G, the width (w) of channel 360 isillustratively 0.147 inches and the depth (d) is illustratively 0.123inches. As water flows toward position H (FIG. 48), the width of channel360 illustratively increases to 0.181 inches, while the depth (d)illustratively remains 0.123 inches. Water continues to flow towardoutlet port 148 and, at position I (FIG. 42), the width (w) of channel360 is illustratively 0.304 inches and the depth (d) is illustratively0.123 inches. Water flows from position Ito position J (FIG. 46) wherethe width (w) is illustratively 0.320 inches and the depth (d)illustratively remains at 0.123 inches. Water flows to position K (FIG.47) and channel 360 illustratively has a width (w) of 0.316 inches and adepth (d) of 0.123 inches in downstream portion 364. Water exits channel360 through outlet port 148, illustratively shown at position L (FIG.40), where the width (w) is 0.314 inches and the depth is 0.123 inches.

By inversely varying the width (w) and the depth (d) to maintain asubstantially constant flow area (A) in upstream portion 362 of channel360, noise and cavitation that may result from sudden changes in thewater pressure are reduced. More particularly, as water transitions todifferent cross-section flow areas (e.g., a smaller flow area from alarger flow area), water pressure may change, resulting in noise andcavitation from the water jetting or stalling. Maintaining asubstantially constant flow area (A) allows water to flow continuouslyat a substantially steady flow rate, or flow velocity, thereby reducingresulting flow restrictions that may cause the water pressure to change.

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe spirit and scope of the invention as described and defined in thefollowing claims.

The invention claimed is:
 1. A valve assembly for controlling water flowand reducing noise in a faucet, the valve assembly including: a valvebody including a hot water inlet, a cold water inlet, and an outlet; alower disc supported by the valve body and including a first portcommunicating with the hot water inlet, a second port communicating withthe cold water inlet, and a third port communicating with the outlet; anupper disc having an upper surface and a lower surface, the lowersurface configured to communicate with the lower disc to define a closedflow channel having a width and a depth, the flow channel providingselective communication between the first and second ports and the thirdport, the width inversely varying with the depth in a first portion ofthe flow channel extending between each of the first and second portsand the third port; and a stem operably coupled to the upper surface ofthe upper disc and configured for selective pivotal movement aboutorthogonal axes extending within a plane parallel to the upper disc. 2.The valve assembly of claim 1, further comprising a second portion ofthe flow channel downstream from the first portion of the channel, aflow area of the second portion being greater than a flow area of thefirst portion.
 3. The valve assembly of claim 2, wherein the width ofthe first portion of the channel decreases in at least one locationwhile the flow area remains substantially constant.
 4. The valveassembly of claim 1, wherein the depth of the channel is less at a firstlocation relative to a second location, the first location positionedcloser to the first and second ports than the second location.
 5. Thevalve assembly of claim 1, wherein the upper disc and the lower disceach define an arcuate perimeter and the channel extends adjacent thearcuate perimeter.
 6. The valve assembly of claim 1, wherein the lowersurface of the upper disc includes a center sealing portion configuredto cooperate with the lower disc to form the channel.
 7. The valveassembly of claim 1, further comprising a temperature limiting memberincluding an engagement surface configured to set a hot water limit forlimiting movement of the stem and the flow of water through the firstport of the lower disc.
 8. A valve assembly for controlling water flowand reducing noise in a faucet, the valve assembly including: a valvebody including a hot water inlet, a cold water inlet, and an outlet; alower disc supported by the valve body and including a first portcorresponding to the hot water inlet, a second port corresponding to thecold water inlet, and a third port corresponding to the outlet; an upperdisc having a lower surface positioned in sealing communication with thelower disc and including an inner channel edge and an outer channel edgedefining a closed channel between the first, second, and third ports,the closed channel having an upstream portion and a downstream portionbetween each of the first and third ports and the second and thirdports, the upstream portion including a width and a depth varyinginversely to reduce downstream flow restrictions, the closed channelextending around a center portion of the lower surface and configured tomix hot water from the first port and cold water from the second portbefore reaching the third port, the center portion of the lower surfaceconfigured to selectively seal the first port and the second port fromthe third port; and a stem operably coupled to the upper disc andconfigured for pivotal movement about orthogonal axes extending within aplane parallel to the upper disc.
 9. The valve assembly of claim 8,wherein a flow area of the downstream portion is greater than a flowarea of the upstream portion.
 10. The valve assembly of claim 9, whereinthe width of the upstream portion of the channel decreases in at leastone location while the flow area remains substantially constant.
 11. Thevalve assembly of claim 8, wherein the depth of the channel is less at afirst location relative to a second location, the first locationpositioned closer to the first and second ports than the secondlocation.
 12. The valve assembly of claim 8, wherein translationalmovement of the upper disc in a first direction moves the inner channeledge to change a water flow rate through the third port, translationalmovement of the upper disc in a second direction perpendicular to thefirst direction changes a proportion of water flow through the first andsecond ports, and translational movement in the first direction from thethird port toward the first and second ports moves the center portion toclose the first and second ports.
 13. The valve assembly of claim 8,wherein the upper disc and the lower disc each define an arcuateperimeter and the channel extends adjacent the arcuate perimeter. 14.The valve assembly of claim 8, further comprising a temperature limitingmember including an engagement surface configured to set a hot waterlimit for limiting movement of the stem assembly and the flow of waterthrough the first port of the lower disc.
 15. A valve assembly forcontrolling water flow and reducing noise in a faucet, the valveassembly including: a valve body including a hot water inlet, a coldwater inlet, and an outlet; a lower disc supported by the valve body andincluding a first port corresponding to the hot water inlet, a secondport corresponding to the cold water inlet, and a third portcorresponding to the outlet; an upper disc having an upper surface and alower surface, the lower surface positioned in communication with thelower disc and including an inner channel edge and an outer channel edgedefining a closed flow channel having a width and a depth, the flowchannel providing selective communication between the first and secondports and the third port, the width inversely varying with the depth ina first portion of the flow channel between each of the first and secondports and third port, the closed peripheral channel configured to mixhot water from the first port and cold water from the second port beforereaching the third port; and a stem assembly including a ball supportedfor pivotal movement about a first axis and a second axis orthogonal tothe first axis, a stem extending upwardly from the ball, and a knuckleextending downwardly from the ball and operably coupled to the uppersurface of the upper disc, the stem assembly providing pivotal movementabout the first axis and the second axis to change a water flow ratethrough the first, second, and third ports.
 16. The valve assembly ofclaim 15, further comprising a second portion of the flow channeldownstream of the first portion, a flow area of the second portion beinggreater than a flow area of the first portion.
 17. The valve assembly ofclaim 16, wherein the width of the first portion of the channeldecreases in at least one location while the flow area remainssubstantially constant.
 18. The valve assembly of claim 15, wherein thedepth of the channel is less at a first location relative to a secondlocation, the first location positioned closer to the first and secondports than the second location.
 19. The valve assembly of claim 15,wherein the lower surface of the upper disc includes a central portionthat defines the channel and extends between the hot water inlet and thecold water inlet.
 20. The valve assembly of claim 15, wherein movementof the stem in a first direction causes movement of the upper disc in asecond direction opposite the first direction.
 21. The valve assembly ofclaim 15, wherein movement of the stem in a direction toward the firstport causes the upper disc to uncover the first port, and movement ofthe stem in a direction toward the second port causes the upper disc touncover the second port.
 22. The valve assembly of claim 15, furthercomprising a temperature limiting member including an engagement surfaceconfigured to set a hot water limit for limiting movement of the stemassembly and the flow of water through the first port of the lower disc.